Regenerative and countertorque braking controller



May 27, 1941. F. w. WENDELBURG ETAL 2,243,590

REGENERATIVE AND COUNTERTORQUB BRAKING CONTROLLER Filed Dec. 4, 1939 2 Sheets-Sheet l L; INVENTOR) WZmddfiw,

ATTORNEY.

y 27, 1941- i F. w. WENDELBURG ETAL 2,243,590

REGENERATIVE AND COUNTERTORQUB BRAKING CONTROLLER INVENTOR J W y M1, 5

ATTORNEY.

Patented May 27, 1941 UNITED STATES PATENT OFFICE msxsasnvs AND OOUN'IIITOIQUE BRAKING comoum I'hls invention relates to circuits for controlling and braking alternating current induction motors and it resides in a novel form of circuit by which there is obtained continuity of switching sequence between regenerative and countertorque braking, a property not heretofore exhibited by circuitsfor alternating current motors. With the circuit connections of this invention the operator may control mine out under load at a high rate ofspeed under regenerative braking and thencheck the rate of speed with any degree of counter-torque braking desired without the interposition of mechanical friction braking at the transition point and transition from counted-torque to regenerative braking may be made at will without the interposition of mechanical friction braking at the transition point and the transition from one to the other and back again my be repeated as freely and as often as desired.

Heretofore in the art polyphsse, wound rotor induction motors with speed control by step-bystep variation of secondary resistance have been employed for load lifting duty. To control lowering of the load with such motors two systems have been employed. The first involves the use of regenerative braking. In this system means are provided for reversing the primary rotation by which, depending upon the secondary resistance selected, lowering speeds, but only those in excess of synchronous speed, may be selected. The second method of lowering involves the use of counter-torque. In this system the same primary rotation employed for hoisting is maintained and secondary resistances high enough to permit the load to overcome the lifting torque to any degree desired are selected. In this system, lowering speeds of any degree, including dead stop, my be obtained, but counter-torque braking when used for continuous duty is attended by substantial energy losses and unnecessary heating.

In an effort to obtain a combination of the advantages of each of the foregoing system, some have heretofore in the art provided a controller which may be moved so as to connect the motor for hoisting, regenerative lowering, or countertorque lowering. In such systems return to open circuit center point, where a mechanical friction solenoid brake is applied to a drum, is necessary each time a transition from one form of braking to the other takes place. It is apparent in such systems that a load dropping rapidly under control of regenerative braking cannot be cushioned and checked by counter-torque braking without mary circuit thereof.

the mechanical shockof first passing through the open circuit center point position where the solenoid brake becomu applied. The abrupt mechanical arresting of the load by the solenoid brake. which becomes applied in advance of the counter-torque braking, thus deprives countertorque brakingof its chief advantage, namely, its smooth electrical cushioning action. By reason of these limitations and others existing in prior structures, no major success has been experienced prior to this invention by thou attempting to make available counter-torque and regenerative braking with alternating current loadlii'ting machinery. As a result, direct current machinery has continued to be used where nicety of control is essential. Through this invention, however, prior existing limitations have been avoided .and a highly versatile control provided.

In aid of the description of this invention and by way of illustration and not of limitation, instances of embodiments of this invention are herein set forth and particularly described with the aid of the accompanying drawings. which form a part hereof.

In the drawings- Fig. l is a circuit diagram of one suitable form of the apparatus of this invention;

Fig. 2 is a circuit diagram of a somewhat simplified form of the apparatus of this invention; and

Fig. 3 is a diagrammatic showing of the control cycle through which a controller handle of an apparatus of this invention will pass.

In Fig. 1 there is set forth a circuit diagram of a form of the apparatus of this invention suitable for use with motors of moderate power and employing magnetic switching in the pri- A threephase wound rotor induction motor is indicated at I. An adjustable external resistance 2 is connected as shown in the secondary circuit of the motor I and 3 provided with taps 8 leading to a controller 4 for a purpose hereinafter to be more fully described. A magnetically-actuated friction brake 5 is mounted to act as shown upon the shaft of motor I. A primary lead 1 leads directly from the motor I to a line connection, as shown, while the primary leads I and I of motor I lead to the magnetic contactors II and II, which together constitute a magnetically-actuated load lead reverser through which the sense of rotation of the primary of motor I may be reversed. I

The magnetically-actuated brake I is provided with a lead it, which is in direct connection with lead 1 andthus in permanent connection with the line. The opposite side of brake 5 is connected through a lead II to brake and interlock relay l4, through which line supply is derived, as shown.

- Magnetic contactor III is arranged to admit load current to the primary of motor I to produce forward rotation thereof and is provided with a forward closing coil l5 arranged to act upon normally open load contactors l8 and I1 and normally closed interlock contactor |8. netically-actuated contactor v|| is arranged to produce reverse rotation of the primary of motor I and is provided with reverse closing coil l9, arranged to act upon normally open load contactors 20 and 2|, normally open interlock contactor 22, and normally closed interlock contactor 23.

Relay |4 serves to control the admission of current to brake 5 and additional purposes to be hereinafter described and is provided with relay closing coil 24, arranged to act upon normally open brake contactor 26 and normally open interlock contactors 21 and 28.

If it be assumed that motor I is applied to a hoisting or load-lifting duty, hoisting movement may be brought about by application of line supply to the primary of motor I through forward contactor l and in order to accomplish this, control current is drawn through supply lead 29 to a controller contactor finger 38, which is brought into contact with controller segment 3| arranged on the hoisting sideof the controller 4, which may be moved in the well-known manner for that purpose. From segment 38 current passes through segment 32, contact finger 33,

leads 34 and 35, to interlock contactor 23, which will be found closed with the controller 4 in the position now under consideration. Connection from interlock contactor 23 is then made through lead 36 with forward closing coil 5, which in turn is connected through lead 31, common return lead 38, and limit switch 39 to lead 1, which is in direct connection with the line. Forward closing coil I is thus energized and forward current supply is furnished to motor To provide for release of brake 5 while load current is being provided to motor I, as above described, a controller segment 40 is provided, which comes into contact with a corresponding contactor finger 4| simultaneously with the engagement of segments 3| and 32 with their respective contactor fingers. Control current is thus supplied through lead 42 to closing coil 24 of relay 4 and from coil 24 return to the opposite line connection is made through common return lead 38, limit switch 39 and lead 1, previously described.

With the controller 4 in any of the several selected controller hoisting positions indicated by the latters A to H, inclusive, adjusted amounts of external resistance 2 are placed in the secondary circuit of motor I through cooperation of the segment group 43 with corresponding contactor fingers contained in contactor finger group 44 in the well-known manner. Upon the return of the controller to the open circuit center point position closing coil l5 becomes deenergized and contactors I8 and I1 open. At the same time closing coil 24 of relay 14 becomes deenergized and brake 5 applied.

In order to perform a lowering operation, the controller 4 is moved so as first to bringrinto contact with respective contactor fingers controller segments 45, 45 and 41. This initial The magmovement of the controller 4 is in a sense a preparatory movement, since it will be observed that segments 48 and 41 coming respectively into contact with fingers 48 and 48 do not serve to form a completed control circuit through leads 58 and 5| by reason of the open condition of contactors 21 and 28 of relay I4 and this condition prevails until controller 4 has been moved in the lowering direction to position E indicated. Upon reaching position E controller segment 52 comes into engagement with contactor finger 4|, whereupon control current is supplied, as previously described, to closing coil 24 of relay l4. Simultaneously with this action a supplementary supply of control current for maintaining relay I 4 in closed position becomes established through segment 41, contact finger 49, lead 5|, contactor 21 and lead 91, so that relay l4 will remain closed so long as segment 41 remains in contact with contact finger 49, even after separation of segment 52 from contactor finger 4|.

Controller 4 is also furnished with a segment 53 which comes into contact with a corresponding contact finger 54 when position E of the lowering stroke of controller 4 is reached and in this manner control current is supplied through lead 55, contactor l8 (which will be found closed with the controller in the position now under discussion), and lead 56 to closing coil IQ of reverse contactor ll. Return connection to the line from closing coil I9 is established through the return lead 51. The coil 9 being thus energized, line connection for reverse rotation of the primary of motor is established through leads 8 and 9, which become connected to the line through contactors 20 and 2|. Thereafter any of the positions E, F, G, or H may be selected to bring about regenerative lowering ofthe load at selected terminal speeds in excess of synchronous speed, such variation in speed being produced by selective engagement of segments contained in segment group 58 with corresponding contactor fingers contained in contactor finger group 44, by means of which selected amounts of external resistance 2 are provided in the secondary circuit of motor To check the rate of descent of the load under regenerative lowering, which will be a relatively high rate, the controller may then be shifted to one of the positions A, B, C, or D. In so doing, controller segment 45 comes into engagement with contactor finger 48, thus furnishing a supply of control current which passes through lead 50, contactor finger 28, lead 60, lead 35, contactor 23, and lead 36 to closing coil l5, and thence through the return lead 31 and limit switch 39 to the line lead 1. Completion of this circuit is rendered possible by disengagement of segment 53 from its respective contactor finger 54, which de-energizes closing coil l9 and causes reverse contactor II to open, thus closing the normally closed contact 23. Line current is thus supplied to the primary of motor in such manner as to produce forward rotation thereof and to produce torque which resists downward travel of the load. The degree to which downward movement of the load is resisted will depend upon which of the controller positions, A, B, C, or D, is selected and which of the segments contained in control segment group 59 remain in contact with their respective contactor fingers contained in group 44.

As previously explained, supplementary control current supply once established through segment 41 remains effective throughout all lowering I 8,848,500 'posiflonsofthecontrollerlandforthisreason transition from regenerative lowering to countertorqueloweringcanbemadeatwillandconversely, counter-tors lowering to regenerative lowering may be made without an intervening s opp e of motor I or application of brake I. From the above it will be further observed that lowering movement of theload canbeproduced onlybyfirstentering the regenerative lowering section of controller 4, but once such entry is made. immediate transition to counter-torque action may be had,'

ifdesired.andunlimited freedomoftransition from counter-torque to regenerative action and back again is available until the controller is again moved to open circuit center point position, whereupon magnetically-controlled friction brake I acts to stop the motor. Controller 6 may thus be said to have an open circuit center point position, a hoisting zone, and a lowering acne comprising a counter-torque section adjacent said open circuit center position and a regenerative lowering section beyond said counter-torque I section. If a situation-should arise in which it is desirable to enter the counter-torque section directly. push button II is provided for this purpose. a

The scope of action of a controller handle suitable for control of controller I is diagrammatically depicted in Fig. 3, wherein there is shown a conventional controller handle 62 arranged for arcuate movement. The handle I! is shown in open circuit center position, in which position solenoid brake l is applied. To the left of handle 62, as indicated by arcuate lines and arrows. is the hoisting zone containing selective hoisting speeds A to H, inclusive. To the right of the handle I! are shown the counter-torque positions A, B, C, and D. arranged along an arouate line, and the regenerative lowering positions E, 1'", G, and H, arranged'along the same arcuate line. To indicate the entrance of control into any of the lowering positions. the arrow I is applied to Fig. 3 so as to join with the regenerative lowering position E. The arrows II and II are applied to the figure to indicate complete freedom of selection of lowering position after entrance through position E. Reentrance of open circuit center position is through the path indicated by the arrow .1. If desired, external resistance corresponding to counter-torque position A may be so selected that suificient countertorque to brmg a certain predetermined load to dead stop may be provided. Great smoothless and precision of control may thus be obtained through the use of a single. easily manipulated and naturally responding control handle.

If. by accident. hoisting is carried to the point where limit switch 39 is opened, the brake I may nevertheless be released and lowering accomplished by moving the controller 4 into lowering position E, or beyond, sincethe closing of reverse contactor ii causes contactor I! to close, thus furnishing, through line II and lead 04, a supplementary return lead connection for relay closs ing coil ll through lead I! and line lead I.

While the use of magnetically-actuated contactors as described above in connection with controller 4, as shown in Fig. l. is distinctly desirable where motors of substantial power are controlled, a direct action controller may be employed in the circuit of this invention, as shown in Fig. 2. In this case a conventional threephase, wound rotor induction motor I may be employed, the primary of which may be supplied through line lead I and through reversing leads II and II which connect said primary for forward or reverse rotation by contactor fingers I! and It on the one hand and for forward rotation by contactor fingers It and II on the other. Contaetor fingers l2 and 14 are of conventional form, while contactor fingers l3 and It are camshaped and free to move with a limited vertical movement so that insulating deflector shoes above segments II and I1 may engage the same upon their upper insulated faces during inward movement and upon the electrical contacting faces of segments 10 and 'll during outward movement, having first passed around the end of said defiectors, and thus supply primary current to the field of motor 0. for forward rotation thereof. Power supply for the controller enters through leads I. and II. which lead to contact fingers II and ll, through which power supply is brought to segments CI and I! when the controller is moved into the lowering zone and through segments l4 and I when the controller is moved into the hoisting zone. A magnetically-actuated brake Ills supplied through lead 81, the latter being in electrical contact with cam contact finger ll arranged to engage an insulated defiector shoe ll upon initial movement into the lowering cone of the controller until reverse field segments I. and II come into engagement with contactor fingers l2 and II, respectively. Thereafter the contact finger II will ride continuously upon the surface of brake release segment 02 until the controller is brought to open circuit center position. with the controller moved into the hoisting zone. primary supply is established through segments 98 and u and brake l! is released through current supplied directly through segment ll. The secondary of motor 0 is provided with adjustable external resistance as, arranged to be adiustably varied in keeping with varying positions of the controller by means of segment groups 0! and III. as shown.

From the foregoing it will be observed that a useful and versatile control system has been provided and that while specific embodiments thereof have been illustrated and described. the advance in the art represented thereby is capable of embodiment in varying forms. It is. therefore, intended that the protection of Letters Patent granted hereon be not unnecessarily limited by the above description, but that the same shall extend to the limits of the inventive advance disdosed herein and as set forth in the claims hereto appended.

What we claim as our invention is:

1. In an electric braking control for induction motors, the combination comprising a magnetically-actuated load lead reverser having a forward closing coil, a reverse closing coil. and an open circuit rest position, an induction motor. means providing for forward and reverse rotation of the primary of said motor under control of said load lead reverser, a magnetically-actuated friction brake for arresting movement for said motor; a magnetically-actuated relay having a coil for closing the same. a pair of closable contacts for controlling said brake, a pair of closable maintaining contacts for maintaining said relay in closed position. and a pair of closable countertorque contacts controlling a path of current sup- P y to the forward coil of said load lead reverser, a movable controller movable through a lowering stroke and a hoisting stroke and having an open circuit center point position, said controller having a plurality of segments energizable during the lowering stroke of said controller, one of which load lead reverser reverse coil is energized, and segments extends throughout the scope of lowmeans for establishing forward driving connecering movement of said controller forming asuptions to said motor during the hoisting stroke ply connection to said relay-maintaining conof said controller. tacts, another of which segments extends 5 3. In a control circuit for alternating current through a, portion of the scope of lowering moveinduction motors suitable for load lifting and ment of said controller spaced from said conand lowering and the like, the combination which troller center point forming a supply connecco p is s 8 m0t0r having 8 P y nd t tion tosald relay-closing coil, another of which da y w ndin a m i ally-a tuated brake segments is coextensiv with the segment ext 10 for arresting movement of said motor, a group of preceding forming a supply connection to said contact segments, a group of contact fingers poload lead reverser reverse coil, and another of sitioned for eng em nt with rr p n in B which segments subtendsthespace lying b tw ments upon relative movement between said the two next preceding segments and said' conp Said s gments and said fingers o p r troll r center point for i supply connection ing to constitute a controller having an open cirto said relay counter-torque contacts and thus cult center point position, a counter-torq Zone to th forward coil of said load lead reverser extending fr m and j ent t s i pen cirwhen said relay coil is energized, leads forming cuit center point position on one side thereof, a return line connections for said load lead reregenerative braking e e te i the Same verser il and said relay il, a d means for 0 .dlrection from and adjacent to said counterestablishing forward driving connection t aid torque zone, a hoisting zone extending from and motor during said hoisting stroke or said cond a nt to sa d p u t center point p troller. I tion on the opposite side thereof, said controller 2. In an electric braking control for induction Segments including a brak d r y per se motors, the combination comprising a magcontacted by a finger g ou e renetically-actuated load lead r v r having a generative and counter-torque zones, a brake and forward closing coil, 8. reverse closing coil, and relay 1 Segment contacted y finger an open circuit rest position; means for precludthroughout the regenerative zone only, a reverse ing simultaneous energizing of both of s id 11 field regenerative lowering segment contacted by an induction motor; means providing for forso a corresponding fin er throu hou he r neraward and reverse rotation of the primary of said tlVe Z0116 8 forward field counter-torque motor under control of said load lead reverser; e t o tacted y a fi er u out th a magnetically-actuated friction brake for arcounter-torque Z0116 o y, it e d forward field resting movement of said m tor; a magneticallyhoisting segment contacted by a corresponding actuated relay having a coil for closing the same, finger ou t the hoisting Zone, direct a pair of closable contacts for controlling said brake S t ntacted by a correspond fi brake, a pair of closable maintaining contacts for ger throughout the hoisting zone, a brake cirmaintaining said relay in closed position, a pair cult controlling means actuated by enfiagemeiit of closable counter-torque conta t furnishing a of said brake and relay keeper segment and said path of current supply to the forward coil of rak and relay closer segment with their r p saidloadlead reverser, amovable controller movtive fingers for releasing and m inta n n said able through a lowering stroke and a hoisting solenoid brake in released condition until disenstroke having an open circuit center point posigflgement 01 d brake d relay keeper e t tion, said controller having a plurality of segfrom its corresponding finger, additional means ments energizable by a line connection during 4 for controlling said brake actuated by engagethe lowering strok thereof, one of which segment of said direct brake segment with its corments extends throughout the lowering stroke of r sp ndin fin er thr u u said t n n said controller forming a supply connection to means actuated by engagement of Said v se said relay-maintaining contacts, another of field regenerative lowering Se t With s 00rwhich segments extends through a portion of r sp nding fin er fo applyin line nn ctionsto the scope of movement of said controller spaced said motor prima y to Produce reverse rotation from said controller center point forming a supthereof, me ns act a by en eme of said ply connection to said relay-closing coil, another forward counter-torque field segment with its of which segments is coextensive with the segc rr pondin fin f r precedent n agement ment next preceding forming a supply connecof said reverse field regenerative lowering segtion to said load lead reverser reverse coil, and ment with its corresponding finger for applying another of which segments subtends the space line connections to said motor primary to prolying between the two next preceding segments duce forward rotation thereof, means actuated and said controller center point forming a supby n ment of said f rw rd h is in fiel s ply connection to said relay counter-torque conment with its corresponding finger for applying tacts and thus to the forward coil of said load line connections to said motor primary to prolead, reverser when said relay coil is energized, duce forward rotation thereof, external variable a lead forming a return line connection for said resistance connected to said motor secondary forward load lead reverser coil and said relay circuit, and means for varying said resistance coil, a limit switch in said lead, a direct lead 6 actuatable in a predetermined manner in comforming a return line connection for said load pany with relative movement between segment lead reverser reverse coil, a lead in addition to and finger groups. that which passes through said limit switch for forming a return lead connection for said brake FRANK W. WENDELBURG. and interlock coil, rendered operative when said RQY J. WADD.

Gil 

